• Transactions of the Korean Society of Automotive Engineers
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• v.4 no.6
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• pp.27-38
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• 1996

A two-dimensional FEM program, which considers bending effects in the membrane fromulation, was developed under plane strain assumption for analyzing forming processes of an arbitrarily shaped draw-die of automotive panels. For the evaluation of bending effects with membrane elements, the bending equivalent forces and stiffnesses are calculated from the bending moment computed using the changes in curvature of the formed shape of two membrane ones. The curves depicted with 3 nodes are described by a circle, a quadratic equation, and a cubic equation, respectively, and in the simulation of the stretch/draw sections of an automotive inner panel, three different description results are compared each other. Also, the bending results are compared with membrane results and measurements in order to verify the validity of the developed program.

• Transactions of the Korean Society of Automotive Engineers
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• v.15 no.1
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• pp.106-115
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• 2007

In this study, first, child headform model was built up, satisfying requirement in the headform validation test. Also, for decreasing both acceleration peak and deformation, a new hood with dome shaped forming in inner panel was investigated. Next, headform impact, complying with draft of EEVC W/G 17, on the central portion of the newly proposed hood were simulated for a steel hood and three aluminum hoods with different thickness for examining the material and thickness effect on HIC value and inner panel deformation. The analysis results explained that aluminum hoods with dome shaped forming in inner panel were highly promising not only for meeting headform safety regulations but also for leading to weight savings. Finally, hood edge design technology in order to reduce pedestrian injury due to the high stiffness of beam type edge and the rigid support, was discussed. Various types of the foam filled edge were designed and their headform safety performance were evaluated. The edge structure with foam filled in upper one third of section exhibited excellent results.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.2
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• pp.174-185
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• 2002

The automotive industry faces many competitive challenges including weight and cost reduction to meet need for higher fuel economy. Tailored blanks offer the opportunity to decrease door weight, reduce manufacturing costs, and improve door stiffness. Optimization technology is applied to the inner panel of a door which is made by tailored blanks. The design of tailored blanks door starts from an existing door. At first, the hinge reinforcement and inner reinforcement are removed to use tailored blanks technology. The number of parts and the welding lines are determined from intuitions and the structural analysis results of the existing door. Size optimization is carried out to find thickness while the stiffness constraints are satisfied. The door hinge system is optimized using design of experiment approach. A commercial optimization software MSC/NASTRAN is utilized for the structural analysis and the optimization processes.

• Transactions of Materials Processing
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• v.20 no.7
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• pp.512-517
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• 2011

TRB(Tailor Rolled Blank) is an emerging manufacturing technology by which engineers are able to change blank thickness continuously within a sheet metal. TRB door inner panels with required larger thicknesses can be used to support localized high loads. In this study, the aluminum alloy 5J32 TRB sheet is used for a door inner panel application. The TRB material properties were varied by using three heat treatment conditions. In order to predict the failure of the aluminum TRB during simulation, the forming limit diagram, which is used in sheet metal forming analysis to determine the criterion for failure, was investigated. Full-field photogrammetric measurement of the TRB deformation was performed with an ARAMIS 3D system. A FE model of the door inner panel was created using Autoform software. The material properties obtained from the tensile tests were used in the numerical model to simulate the door inner of AA 5J32 for each heat treatment condition. After finite element analysis for the evaluation of formability, a prototype front door panel was manufactured using a hydraulic press.

• International Journal of Aerospace System Engineering
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• v.3 no.1
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• pp.21-24
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• 2016

In this study, a optimal design on the hood automotive using eco-friendly natural fiber composites is performed. The hood of an automobile is determined by dividing the Inner panel shape through optimization phase to outer panel and inner panel. It was performed to optimize the size of the thickness of the inner panel and the outer panel by applying a flax/epoxy composite materials. The optimized shape was evaluated for weight-lightening, stability and the pedestrian collision safety. Through the resin flow analysis are confirmed to molding possibility judgment of product.

• Transactions of the Korean Society of Automotive Engineers
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• v.10 no.2
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• pp.228-233
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• 2002

TWB(Tailor Welded Blanks) is one of the recent techniques to reduce the weight and cost of the body members. To apply the TWB technique, we must decide the position of the welding line and the thickness of the welded blanks. Although many researchers have tried to check the formability of welded blanks, there are not so many researches from the structural point of view. In this paper, the TWB technique is applied to combine the door inner panel and the hinge face panel into one piece. The finite element structural analysis of the door assembly leads to the final design of the tailor welded door inner panel, which shows the mass reduction of 1.08kg without the sacrifice of the structural stiffness. The structural stiffness analysis includes the frame stiffness analysis, the belt line stiffness analysis, the door sagging analysis and the vibration analysis.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2005.10a
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• pp.75-78
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• 2005

The static implicit finite element method is applied effectively to analyze back inner panel stamping processes, which include the forming stage Analysis results examining possibility and validity of the formulation and the factor of study are presented. Further, the simulated results for f/apron panel stamping processes are shown and discussed. Its application is being increased especially in the automotive industrial area for the cost reduction, weight saving, and improvement of strength.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1998.06a
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• pp.33-40
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• 1998

In recent domestic automotive industry, applications of computer simulation to the manufacturing of stamping dies for inner and outer body panels which greatly affect durability and aesthetic quality of automobiles, have been increased. Enhancement of die quality, and reduction of total die manufacturing time and consequently manufacturing cost are the visible outcome. However, to successfully apply the result of simulation by a commercial package to the die manufacturing, development of an optimal die manufacturing process is required upon the completion of analysis of forte and shortcomings of available sheet metal forming softwares in the market. Based on the results of numerical analysis of front door outer panel forming, this paper evaluates the applicability of simulation results to the real die making for automotive body panels. Also, it attempts to select an optimal die manufacturing process including design, machining and tryout. Lastly, it discusses the expected effects by adopting the selected process in a real stamping die manufacturing facility.

• Transactions of Materials Processing
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• v.10 no.3
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• pp.193-199
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• 2001

Forming more than two parts of sheet metal in a single stamping operation lowers production costs, reduces weight, and heightens dimensional accuracy. The tailored blank (TB) is a laser-welded or mash-seam-welded sheet metal with different thicknesses, different strengths, or different coatings. Recently, automotive manufacturers have been interested in tailored blanks because of their desire to improve the rigidity, weight reduction, crash durability, and cost savings. Therefore the application to auto-bodies has increased. However, as tailored blanks do not behave like un-welded blanks in press forming operations, stamping engineers no longer rely on conventional forming techniques. Field try-outs are very important manufacturing processes for an economic die-making. In the field try-outs, the rounded geometries of tool and the drawbead shape and size in die face are generally modified when the forming defects can not be removed by the adjustment of forming process parameters. In this study, the field try-outs of tailored door inner panel are introduced and evaluated. The behaviours of laser tailored blank associated with different thickness combinations in the forming process of door inner panel are described focusing on terms of experimental investigations on the formability.

• Journal of the korean Society of Automotive Engineers
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• v.12 no.6
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• pp.48-59
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• 1990

A finite element program was developed using line elements for simulating the stretch/draw forming operation of an arbitrarily-shaped plane-strain section. An implicit, incremental, updated Lagrangian formulation is employed, introducing a minimum plastic work path assumption for each time step. Geometric and material nonlinearities are also considered within each time step. The finite element equation is based on the mesh-normal, which compatibly describes arbitrary tool surfaces and FEM meshes without depending on the explicit spatial derivatives of tool surfaces. The membrane approximation is adopted under the plane stress assumption. The sheet material is assumed to obey a rigid-viscoplastic constitutive law. The developed program was tested in the die-tryout of typical automotive inner panels. In order to determine a single friction coefficient and boundary length, FEM results and measurements of thinning for a stretched section of final die were compared. After finding analysis parameters, the sheet forming operations of original and final die designs were simulated. Excellent agreement between measured and computed thickness strains was obtained and the developed program was able to identify die designs which were rejected during die tryout.